Loosen the tensioner from it's temporary position so the spring pressure will allow it to contact the timing belt.

Rotate the crankshaft 2 complete turns in the normal rotation direction to remove any belt slack. Turn the crankshaft until the timing marks are lined up. If the timing has slipped, remove the belt and repeat the procedure.

Tighten the tensioner mounting bolts, slotted side (right) first, then the spring side.

Once again rotate the engine 2 complete revolutions until the timing marks align. Recheck the belt tension.

When the tension side of the timing belt and the tensioner are pushed in horizontally with a moderate force, about 11 lbs. (15 N). and the cogged side of the belt covers about1/4in. (6.35mm) of the tensioner right side mounting bolt head, the across flats, the tension is correct.

Fig. Fig. 13: With the holes aligned, lock the tensioner by inserting a 1.4mm dia. wire through the holes - 1.6L engine

Fig. Fig. 14: Installing the tensioner pulley - 1.6L engine

Fig. Fig. 15: Camshaft sprocket timing alignment - 1.6L engine

Make sure the timing marks are aligned. Remove the binder clips. Rotate the crankshaft a
1
/
4
turn counter-clockwise. Then turn the crankshaft clockwise until the timing marks are aligned.

Place special tool MD998752 or equivalent, on a torque wrench. Insert the tool into the place provided on the tension pulley. Loosen the center pulley bolt and apply 2.2 ft. lbs. (3.1 Nm) of pressure against the timing belt with the tension pulley. While holding the required torque, tighten the center bolt. Screw in special tool MD998738 or equivalent, through the left engine support bracket until it contacts the tensioner arm bracket. Turn the tool a little more to secure the tensioner and remove the locking wire placed into the automatic adjuster when it was reset.

Fig. Fig. 16: The camshaft sprockets are interchangeable. When the sprocket is mounted on the exhaust side, use the timing mark on the right and vice-versa - 1.6L engine

Remove the special tool. Rotate the crankshaft 2 complete turns clockwise and allow it to set, for about 15 minutes. Then measure the protrusion of the automatic adjuster. It should be 3.8-4.5mm. If the proper amount of protrusion is not present, repeat the tensioning process.

Install the upper and lower timing belt covers.

Install the crankshaft pulley and water pump pulley.

Install the alternator and power steering drive belts. Install the air conditioner drive belt and tensioner assembly.

Ensure that the sprocket timing marks are aligned, before making the adjustment.

Fig. Fig. 22: Installing tensioner - 1990 1.8L engine

Fig. Fig. 23: Timing belt installed - 1990 1.8L engine

Fig. Fig. 24: Rotate the crankshaft clockwise until the timing mark on the camshaft sprocket is 2 teeth past the timing mark on the cover - 1990 1.8L engine

Fig. Fig. 25: To properly tension the belt, apply force to the tensioner, in the direction of the arrow, so that the belt meshes completely with the camshaft sprocket, without floating over portion A. Tighten first the nut, then the bolt - 1990 1.8L engine

Loosen the tensioner mounting bolt and nut and allow the spring tension to move the tensioner against the belt.

Make sure the belt comes in complete mesh with the sprocket by lightly pushing the tensioner up by hand toward the mounting nut.

Tighten the tensioner mounting nut and bolt.

Be sure to tighten the nut before tightening the bolt. Too much tension could result from tightening the bolt first.

Fig. Fig. 26: Check the belt-to-cover clearance - 1990 1.8L engine

Fig. Fig. 27: Timing cover installation - 1990 1.8L engine

Recheck all sprocket alignments.

Turn the crankshaft through a complete rotation in the normal direction. Do not turn in a reverse direction or shake or push the belt.

Loosen the tensioner bolt and nut. Retighten the nut and then the bolt.

Loosen the tensioner from it's temporary position so the spring pressure will allow it to contact the timing belt.

Rotate the crankshaft 2 complete turns in the normal rotation direction to remove any belt slack. Turn the crankshaft until the timing marks are lined up. If the timing has slipped, remove the belt and repeat the procedure.

Tighten the tensioner mounting bolts, slotted side (right) first, then the spring side.

Once again rotate the engine 2 complete revolutions until the timing marks align. Recheck the belt tension.

When the tension side of the timing belt and the tensioner are pushed in horizontally with a moderate force, about 11 lbs. (15 N). and the cogged side of the belt covers about1/4in. (6.35mm) of the tensioner right side mounting bolt head, the across flats, the tension is correct.

Fig. Fig. 47: Check that there are no belt teeth in the section marked with a star, and secure the tensioner pulley. When this is done, check belt deflection at A. Deflection should be about 1.18mm - 1992-93 1.8L engine

Fig. Fig. 52: Place the upper end of the tensioner spring against the water pump body - 2.4L engine

Fig. Fig. 53: Pre-tensioniong position - 2.4L engine

Fig. Fig. 54: Timing belt installation - 2.4L engine

To adjust the timing (outer) belt, first loosen the pivot side tensioner bolt and then the slot side bolt. Allow the spring to take up the slack.

Fig. Fig. 55: After aligning the timing mark on the oil pump sprocket, remove the cylinder block plug and install an 8mm dia. rod. The rod should go in 60mm deep, or more. If the rod can be inserted only 20-25mm, turn the sprocket one revolution and try again. Leave the screwdriver in until the timing belt is installed - 2.4L engine

Fig. Fig. 56: Rotate the crankshaft clockwise until the timing mark on the camshaft sprocket is 2 teeth past the timing mark on the cover - 2.4L engine

Fig. Fig. 57: To properly tension the belt, apply force to the tensioner, in the direction of the arrow, so that the belt meshes completely with the camshaft sprocket, without floating over portion A. Tighten first bolt A, then bolt B - 2.4L engine

Check to make sure the timing marks on each sprocket are aligned. Turn the crankshaft in normal direction (clockwise), by 2 teeth of the crankshaft sprocket.

The purpose of step 5 is to apply the proper amount of tension to the tension side of the timing belt, be sure not to turn the crankshaft in the opposite direction (counterclockwise).

Tighten the slot side tensioner bolt and then the pivot side bolt. If the pivot side bolt is tightened first, the tensioner could turn with bolt, causing over tension.

Fig. Fig. 61: Apply pressure to the tensioner so that the belt is taut - 2.4L engine

Lightly clamp the center of the span between the camshaft sprocket and the water pump sprocket on the belt tension side with a thumb and forefinger. Check to be sure the clearance between the reverse surface of the belt and the inside of the undercover seal line is at the standard value.

The timing chain case is cast aluminum, so exercise caution when handling this part.

1.5L Engine

Turn the engine until the No. 1 piston is on TDC with the timing marks aligned.

Disconnect the negative battery cable.

Remove the fan drive belt, the fan blades, spacer and water pump pulley.

Remove the timing belt cover.

Loosen the timing belt tensioner mounting bolt and move the tensioner toward the water pump. Temporarily secure the tensioner.

Remove the crankshaft pulley and slide the belt off of the camshaft and crankshaft drive sprockets.

Inspect the drive sprockets for abnormal wear, cracks or damage and replace, if necessary. Remove and inspect the tensioner. Check for smooth pulley rotation, excessive play or noise. Replace tensioner, if necessary.

To install:

Reinstall the tensioner, if removed and temporarily secure it close to the water pump.

Make sure the timing mark on the camshaft sprocket is aligned with the pointer on the cylinder head and that the crankshaft sprocket mark is aligned with the mark on the engine case.

Install the timing belt on the crankshaft sprocket.

Install the belt counterclockwise over the camshaft sprocket making sure there is no play on the tension side of the belt. Adjust the belt fore and aft so it is centered on the sprockets.

Loosen the tensioner from it's temporary position so the spring pressure will allow it to contact the timing belt.

Rotate the crankshaft 2 complete turns in the normal rotation direction to remove any belt slack. Turn the crankshaft until the timing marks are lined up. If the timing has slipped, remove the belt and repeat the procedure.

Tighten the tensioner mounting bolts, slotted side (right) first, then the spring side.

Once again rotate the engine 2 complete revolutions until the timing marks line up. Recheck the belt tension.

When the tension side of the timing belt and the tensioner are pushed in horizontally with a moderate force, about 11 lbs. (15 N) and the cogged side of the belt covers about1/4in. (6.35mm) of the tensioner right side mounting bolt head the across flats, the tension is correct.

Raise the vehicle and support it safely. Remove the under engine splash shield.

Place a piece of wood on a suitable floor jack and support the engine. Remove the engine mount bracket.

Remove the alternator and power steering drive belts. Remove the air conditioner drive belt and tensioner assembly.

Remove the water pump pulley and the crankshaft pulley.

Remove the upper and lower timing belt covers.

Remove the engine center cover. Remove the breather hose from the rear of the rocker cover. Remove the PCV hose. Disconnect the spark plug cables from the plugs.

Remove the rocker cover and rear half-moon seal.

Confirm the engine is still at No. 1 TDC. The timing marks on the camshaft sprocket and the upper surface of the cylinder head should coincide. The dowel pin on the front of the camshafts should be in the 12 o'clock position. Remove the automatic belt tensioner. Loosen the tensioner pulley center bolt.

If the timing belt is to be reused, mark an arrow, on the belt, in the direction of rotation, for installation reference. Remove the timing belt.

To install:

Install the automatic tensioner, after reset.

To reset the tensioner: Keep the adjuster level and clamp it in a soft jawed vise. Clamp with the extended adjuster on one side and the end mounting a plug on the other side. If the plug extends out of the adjuster body, place a suitable hole sized washer over the plug so the vise jaw pushes on the washer, not the plug. Close the vise slowly, forcing the adjuster back into the body. When the hole in the adjuster boss aligns with the adjuster rod, insert a snug fitting pin or wire into the holes to keep the rod in the compressed position. With the locking pin or wire in place, install the tensioner.

Align the timing marks on the camshaft sprockets. Align the crankshaft timing marks. Align the oil pump timing marks. Place the timing belt around the intake camshaft and secure it to the sprocket with a stationary binder spring clip. Install the timing belt around the exhaust camshaft sprocket, check sprocket marks for alignment and secure the belt with a second binder clip on the exhaust sprocket.

Lift up the tensioner pulley against the belt and tighten the center bolt to hold it in position.

Check to see that all of the timing marks are aligned. Remove the binder clips. Rotate the crankshaft a quarter turn counter clockwise. Then turn the crankshaft clockwise until the timing marks are aligned.

Place special tool MD998752 or equivalent, on a torque wrench. Insert the tool into the place provided on the tension pulley. Loosen the center pulley bolt and apply 2.2 ft. lbs. (3.0 Nm) of pressure against the timing belt with the tension pulley. While holding the required torque, tighten the center bolt. Screw in special tool MD998738 or equivalent, through the left engine support bracket until it contacts the tensioner arm bracket. Turn the tool a little more to secure the tensioner and remove the locking wire place into the automatic adjuster when it was reset.

Remove the special tool. Rotate the crankshaft 2 complete turns clockwise and allow it to sit for about 15 minutes. Then measure the protrusion of the automatic adjuster. It should be 0.015-0.018 in. (0.381-0.457mm). If the proper amount of protrusion is not present, repeat the tensioning process.

1990 1.8L Engine

Drain the coolant. Disconnect the negative battery cable.

Remove the alternator and accessory belts. Remove the belt cover.

Rotate the crankshaft to bring No. 1 piston to TDC on the compression stroke. Align the notch on the crankshaft pulley with the T mark on the timing indicator scale and the timing mark on the upper under cover of the timing belt with the mark on the camshaft sprocket. Mark and remove the distributor.

Remove the crankshaft pulley and bolt.

Remove the lower splash shield, if necessary.

Remove the timing belt covers, upper front and lower front.

Remove the crankshaft sprocket bolt.

Loosen the tensioner mounting nut and bolt. Move the tensioner away from the belt and retighten the nut to keep the tensioner in the off position. Remove the belt.

Install the tensioner spring and tensioner. Temporarily tighten the nut. Install the front end of the tensioner spring (bent at right angles) on the projection of the tensioner and the other end (straight) on the water pump body.

Loosen the nut and move the tensioner in the direction of the water pump. Lock it by tightening the nut.

Ensure that the sprocket timing marks are aligned and install the timing belt. The belt should be installed on the crankshaft sprocket, the oil pump sprocket and then the camshaft sprocket, in that order, while keeping the belt tight.

Loosen the tensioner mounting bolt and nut and allow the spring tension to move the tensioner against the belt.

Make sure the belt comes in complete mesh with the sprocket by lightly pushing the tensioner up by hand toward the mounting nut.

Tighten the tensioner mounting nut and bolt.

Be sure to tighten the nut before tightening the bolt. Too much tension could result from tightening the bolt first.

Recheck all sprocket alignments.

Turn the crankshaft through a complete rotation in the normal direction. Do not turn in a reverse direction or shake or push the belt.

Loosen the tensioner bolt and nut. Retighten the nut and then the bolt.

Raise and safely support the weight of the engine using the appropriate equipment. Remove the front engine mount bracket and accessory drive belts.

Remove the coolant reservoir tank.

Remove timing belt upper and lower covers.

Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction if it is to be reused. Loosen the timing belt tensioner and remove the timing belt.

NOTE:If coolant or engine oil comes in contact with the timing belt, they will drastically shorten its life. Also, do not allow engine oil or coolant to contact the timing belt sprockets or tensioner assembly.

Remove the tensioner spacer, tensioner spring and tensioner assembly.

Inspect the timing belt for cracks on back surface, sides, bottom and check for separated canvas. Check the tensioner pulley for smooth rotation.

To install:

Position the tensioner, tensioner spring and tensioner spacer on engine block.

Align the timing marks on the camshaft sprocket and crankshaft sprocket. This will position No. 1 piston on TDC on the compression stroke.

Position the timing belt on the crankshaft sprocket and keeping the tension side of the belt tight, set it on the camshaft sprocket.

Apply counterclockwise force to the camshaft sprocket to give tension to the belt and make sure all timing marks are aligned.

Loosen the pivot side tensioner bolt and the slot side bolt. Allow the spring to take up the slack.

Tighten the slot side tensioner bolt and then the pivot side bolt. If the pivot side bolt is tightened first, the tensioner could turn with bolt, causing over tension.

Turn the crankshaft clockwise. Loosen the pivot side tensioner bolt and then the slot side bolt to allow the spring to take up any remaining slack. Tighten the adjuster bolt to 18 ft. lbs. (24 Nm).

Check the belt tension by holding the tensioner and timing belt together by hand and give the belt a slight thumb pressure at a point level with tensioner center. Make sure the belt cog crest comes as deep as about
1
/
4
of the width of the slot side tensioner bolt head. Do not manually overtighten the belt or it will howl.

Install the timing belt covers and all related items.

Connect the negative battery cable.

2.0L and 2.4L Engines

An 8mm diameter metal bar is needed for this procedure.

Disconnect the negative battery cable. Remove the water pump drive belt and pulley.

Remove the crank adapter and crankshaft pulley.

Remove the upper and lower timing belt covers.

Move the tensioner fully in the direction of the water pump and temporarily secure it there.

If the timing belt is to be reused, make a paint mark on the belt to indicate the direction of rotation. Slip the belt from the sprockets.

Remove the camshaft sprocket bolt and pull the sprocket from the camshaft.

Remove the crankshaft sprocket bolt and pull the crankshaft sprocket and flange from the crankshaft.

Remove the plug on the left side of the block and insert an 8mm diameter metal bar in the opening to keep the silent shaft in position.

Loosen the right silent shaft sprocket mounting bolt until it can be turned by hand.

Remove the belt tensioner and remove the timing belt.

Do not attempt to turn the silent shaft sprocket or loosen its bolt while the belt is off.

Remove the silent shaft belt sprocket from the crankshaft.

Check the belt for wear, damage or glossing. Replace it if any cracks, damage, brittleness or excessive wear are found.

Check the tensioners for a smooth rate of movement.

Replace any tensioner that shows grease leakage through the seal.

To install:

Install the silent shaft belt sprocket on the crankshaft, with the flat face toward the engine.

Apply light engine oil on the outer face of the spacer and install the spacer on the right silent shaft. The side with the rounded shoulder faces the engine.

Install the sprocket on the right silent shaft and install the bolt but do not tighten completely at this time.

Align the silent shaft and oil pump sprockets using the timing marks. If the 8mm metal bar can not be inserted into the hole 2.36 in. (60mm), the oil pump sprocket will have to be turned 1 full rotation until the bar can be inserted to the full length. If this procedure is not followed, the engine will run but vibrate at high engine rpm.

Install the silent shaft belt and adjust the tension, by moving the tensioner into contact with the belt, tight enough to remove all slack. Tighten the tensioner bolt to 21 ft. lbs. (28 Nm).

Tighten the silent shaft sprocket bolt to 28 ft. lbs. (38 Nm).

Install the flange and crankshaft sprocket on the crankshaft. The flange conforms to the front of the silent shaft sprocket and the timing belt sprocket is installed with the flat face toward the engine.

The flange must be installed correctly or a broken belt will result.

Install the washer and bolt in the crankshaft and torque it to 94 ft. lbs. (127 Nm).

Install the camshaft sprocket and bolt and torque the bolt to 72 ft. lbs. (98 Nm).

Install the timing belt tensioner, spacer and spring.

Align the timing mark on each sprocket with the corresponding mark on the front case.

Install the timing belt on the sprockets and move the tensioner against the belt with sufficient force to allow a deflection of 5-7mm along its longest straight run.

Tighten the tensioner bolt to 21 ft. lbs. (28 Nm).

Install the upper and lower covers, the crankshaft pulley and the crank adapter. Tighten the bolts to 21 ft. lbs. (28 Nm).

Remove the 8mm bar and install the plug. Connect the negative battery cable.

SILENT SHAFT BELT REPLACEMENT

2.0L and 2.4L Engines

When replacing the timing belt, the manufacturer recommends to replace the silent shaft belt.

After removing the timing belt, mark arrows on the belt to indicate direction of rotation (clockwise).

If the silent shaft belt is not installed properly, the engine will run but with a vibration. Align the silent shaft and oil pump sprockets using the timing marks. If the 8mm metal bar can not be inserted into the hole 2.36 inch (60mm), the oil pump sprocket will have to turned 1 full rotation until the bar can be inserted to the full length.

Align the timing marks before removal. Loosen the belt tensioner and remove the belt.

To install:

Make sure the crankshaft and silent shaft sprocket timing marks are aligned.

Fit the belt over the sprockets. Make sure there is no slack in the belt.

Temporarily fix the timing belt tensioner so that the center of the tensioner pulley is to the left and above the center of the installation bolt. Temporarily attach the tensioner pulley so that the flange is toward the front of the engine.

Adjust the belt so that the slack between the 2 sprockets is within 0.20-0.28 inch (5-7mm).